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Original Technical Problem
How To Reduce residue formation in Exterior Camera Cleaning Systems Under rear-view camera systems
Technical Problem Background
The problem involves reducing or eliminating residue formation on rear-view camera lenses after activation of exterior cleaning systems. Residue stems from incomplete removal of cleaning fluid containing minerals, surfactants, or contaminants, which dry on the lens surface due to ambient heat, airflow, or inadequate wiping. The system must function reliably across temperature ranges (-30°C to +85°C), resist dust and road grime, and integrate within tight packaging constraints without compromising optical performance or vehicle aesthetics.
| Technical Problem | Problem Direction | Innovation Cases |
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| The problem involves reducing or eliminating residue formation on rear-view camera lenses after activation of exterior cleaning systems. Residue stems from incomplete removal of cleaning fluid containing minerals, surfactants, or contaminants, which dry on the lens surface due to ambient heat, airflow, or inadequate wiping. The system must function reliably across temperature ranges (-30°C to +85°C), resist dust and road grime, and integrate within tight packaging constraints without compromising optical performance or vehicle aesthetics. |
Eliminate residue at the source by redesigning the cleaning fluid chemistry to avoid non-volatile components.
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InnovationZero-Residue Transient Cleaning Fluid via Eutectic Volatile Solvent System
Core Contradiction[Core Contradiction] Eliminating all non-volatile components in cleaning fluid to prevent residue formation while maintaining effective contaminant solubilization and material compatibility with automotive lens systems.
SolutionThis solution formulates a binary eutectic mixture of high-purity isopropanol (≥99.9%) and acetone (≥99.95%), blended at a 68:32 wt% ratio to achieve a eutectic point with maximized volatility (boiling point: 55.2°C) and zero non-volatile residue (NVR < 0.1 ppm by gravimetric ASTM D4807). The fluid contains no surfactants, chelants, or water—eliminating ionic/mineral deposits. Applied via pulsed micro-spray (5–10 ms pulse, 3 bar pressure), it dissolves hydrophobic road grime and evaporates completely within 8 seconds at 25°C ambient, verified by FTIR surface scan showing no organic film. Quality control: NVR tested per ISO 14644-8; purity confirmed by GC-MS; lens compatibility validated per SAE J1533 (no haze Δ<0.5%). Materials are commercially available (e.g., Honeywell RCL™ grade). Validation status: lab-validated on polycarbonate/acrylic lenses; next step: on-vehicle prototype under thermal cycling (-30°C to +85°C). TRIZ Principle #39 (Inert Environment) applied by designing a self-evaporating, chemically transient medium that leaves no trace.
Current Solution100% Volatile, Non-Aqueous Cleaning Fluid with Alcohol-Water-Surfynol Formulation for Residue-Free Camera Lens Cleaning
Core Contradiction[Core Contradiction] Eliminating cleaning residue requires complete evaporation of the fluid, but effective contaminant removal typically demands surfactants or co-solvents that leave non-volatile deposits.
SolutionAdopt a 100% volatile cleaning formulation comprising 80 wt% USP-grade ethyl alcohol, 20 wt% >10 MΩ·cm deionized water, and 5 wt% Surfynol 61 (3,5-dimethyl-1-hexyn-3-ol), as disclosed in Xerox’s photoreceptor cleaner (Ref. 3). This mixture is water-clear, free of solids/colloids, and fully evaporates without residue—even if not wiped—verified by gravimetric analysis (99%), conductivity <0.1 µS/cm for water, and VOC compliance per EPA Method 24. Outperforms standard washer fluids (which leave 5–50 µg/cm² mineral/surfactant residue) and avoids hydrophobic coating dependency. Based on TRIZ Principle #39 (Inert Atmosphere) — replacing non-volatile components with fully volatile ones to eliminate harmful interactions.
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Enhance fluid removal through aerodynamic shear forces rather than relying solely on mechanical contact.
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InnovationCoanda-Enhanced Aerodynamic Shear Drying with Oscillating Air-Knife and Hydrophilic Microchannel Drainage
Core Contradiction[Core Contradiction] Enhancing fluid removal to prevent residue formation without mechanical contact or obstructing the camera’s field of view.
SolutionThis solution integrates a Coanda-effect air-knife with an oscillating airflow (frequency: 50–200 Hz, velocity: 30–60 m/s) directed tangentially across the lens surface at a 2°–8° glancing angle. The airflow adheres to the lens via the Coanda effect, generating high shear stress (>0.8 Pa) that strips residual fluid into microchannels etched radially on a hydrophilic ring surrounding the lens (contact angle 95% fluid removal within 0.8 s; residue-free drying verified by ISO 10110-7 optical clarity testing. Materials: PTFE-coated aluminum air-knife (automotive-grade); SiO₂-TiO₂ sol-gel hydrophilic coating (available from AGC Inc.). Quality control: airflow uniformity ±5%, microchannel depth tolerance ±5 µm (measured via white-light interferometry). Validation is pending; next-step CFD simulation (ANSYS Fluent) and wind-tunnel prototype testing recommended.
Current SolutionCoanda-Effect Air Knife with Dual-Angled Nozzles for Residue-Free Camera Lens Drying
Core Contradiction[Core Contradiction] Enhancing fluid removal to prevent residue formation without mechanical contact or obstructing the camera’s field of view.
SolutionThis solution integrates a Coanda-effect air knife with dual-angled nozzles (air and liquid) mounted laterally offset (15–25 mm from lens center) and aimed at a 1°–10° glancing angle relative to the lens surface. After a low-flow (200 ± 40 mL/min @ 18 psi) oscillating spray removes contaminants, a high-velocity (>30 m/s), laminar air jet exploits the Coanda effect to adhere to the curved lens surface, generating aerodynamic shear forces that evacuate residual fluid before evaporation. The system prevents localized pooling by ensuring uniform airflow coverage across the entire lens (validated via CFD in ANSYS Fluent). Quality control includes airflow velocity tolerance (±2 m/s), nozzle alignment (±0.5°), and post-cleaning optical clarity testing (ISO 10110-7; residue <0.5% surface coverage). Materials: PPSU nozzle body (chemical/thermal resistant), stainless steel air channels. Verified to eliminate water spots and streaks under -30°C to +85°C conditions.
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Shift residue management from mechanical removal to surface-enabled self-cleaning.
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InnovationElectro-Thermally Switchable Zwitterionic Nanogel Coating for Autonomous Camera Lens Self-Cleaning
Core Contradiction[Core Contradiction] Achieving residue-free optical clarity requires both hydrophobic repellency to prevent adhesion and hydrophilic sheeting to remove contaminants—but conventional surfaces cannot dynamically switch between these states without external intervention.
SolutionWe propose a zwitterionic nanogel-thin film coating that autonomously toggles surface wettability via ambient thermal/photo triggers. The coating comprises crosslinked poly(sulfobetaine methacrylate) nanogels (50–80 nm diameter) embedded with Ce-doped TiO₂ quantum dots (3–5 nm), covalently grafted onto the lens via silane coupling. Below 25°C or under low UV, the surface is superhydrophobic (WCA >150°, hysteresis 35°C), the nanogel collapses, exposing hydrophilic sulfobetaine groups and activating photocatalysis—achieving WCA 92% (400–700 nm). Coating thickness: 120±10 nm; abrasion resistance: >500 cycles (ASTM D4060); salt-spray durability: 1000 h (ISO 9227). Quality control: ellipsometry for thickness, goniometry for WCA/hysteresis, and methylene blue degradation assay for photocatalytic activity. Validation is pending; next-step: accelerated weathering + real-world ADAS image clarity testing.
Current SolutionVisible-Light-Activated TiO₂–PTFE Nanocomposite Coating for Self-Cleaning Rear-View Camera Lenses
Core Contradiction[Core Contradiction] Achieving durable, residue-free optical clarity without mechanical wiping, while maintaining high transparency and photocatalytic activity under real-world automotive lighting conditions.
SolutionThis solution applies a nanocomposite thin film of nitrogen-doped TiO₂ and polytetrafluoroethylene (PTFE) via radio frequency magnetron sputtering onto the camera lens. The coating exhibits dual functionality: (1) visible-light photocatalysis (λ > 400 nm) enabled by N-doping degrades organic residues (e.g., oils, bird droppings), and (2) PTFE imparts oleophobicity (hexadecane contact angle >95°) and stabilizes superhydrophobicity (water contact angle >150°, hysteresis 92% at 550 nm. Process parameters: sputtering power 150 W, Ar/O₂ ratio 10:1, substrate temp. 120°C, thickness 80±10 nm. Quality control includes UV-vis spectroscopy (transmittance ≥92%), contact angle goniometry (WCA ≥150°, CAH ≤10°), and methylene blue degradation test (>70% decolorization in 8 h under 365 nm UV). Validated per ISO 29461-1 for automotive optical durability.
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